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Confirm all components are present by comparing them with the parts list on the instruction sheet.
Unfold the box, form the rear triangle, and prepare the side, top, and bottom flaps for closure.
Fold and connect front flaps, then secure the bottom using numbered tabs and tape.
Attach transit plate or wheel truck, then flip the box upright, ensuring correct orientation.
Fold and fit the large corrugated inserts into the box shell, locking them securely.
Prepare the bicycle by marking, removing components, and mounting the fork securely.
Install small inserts and secure the saddle, front wheel, and rear wheel within the box.
Close the top flaps, matching numbered sections, and seal the box edges with tape.
Learn how to move the box with the wheel truck and stack multiple containers.
This document describes the AirCaddy K9100 Compact (Basic AirCaddy) and the optional K8350 Aircraft Kit, providing instructions for assembling the shipping container for bicycles.
The AirCaddy K9100 Compact is a bicycle shipping container designed to protect a bicycle during transit. It is a corrugated box system that allows for the secure packing of a bicycle by disassembling certain components and fitting them within the box. The system aims to provide a worldwide cycling solution through creative innovations, ensuring the safe transport of bicycles. The K8350 Aircraft Kit is an optional addition that includes a metal wheel truck for easier mobility of the packed box, particularly useful for airport handling.
Before starting, verify all components listed for the K9100 Compact and K8350 Aircraft Kit (if purchased) are present.
Unfold the main corrugated box (B1000-00) so it resembles a butterfly from the top. Ensure the box is upside-down, with arrows and writing also upside-down.
Continue unfolding the rear of the box until it forms a triangle. The side facing you is the "front" of the box, and the narrow point is the "rear."
Unfold all four side flaps (top and bottom) of the box.
Pull the two small front flaps from the inside of the box to the outside.
Flip the side flaps over to begin forming the closed bottom of the box.
Flip the front flaps over so they rest on top of the side flap (folded in the previous step). Connect matching numbers (e.g., "1" with "1").
Flip the last big flap over to completely close the bottom, matching number "2" with "2". Tape the free edges of the box with six or seven 8-inch strips to bridge the edges. Then, use a long, continuous strip to completely seal the edges.
Place the metal transit plate (B3210-00) or the optional metal wheel truck (T3230-00) at the front of the bottom of the box. Ensure the studs go through the holes into the box, connecting "3" on the plate/truck with "3" on the container.
Carefully flip the box over while holding the transit plate/wheel truck in place. The lettering and arrows should now point upright. Pull the small flaps from the inside of the box to the outside.
Fold each large corrugated insert (C3755-00) as shown in the diagrams (steps A-E). Lay an insert on a flat surface with the "A"s closest to you. Fold up the small flap at the far end (B). Crease the three folds at the near end (C) and crease them to show the two letter "A"s (D). Stand up the insert (E). Put both inserts into the shell (F). Lock the green tab of one insert into the slot of the other (G). Push the locked inserts flat against the rear of the shell to form two triangles in the corners (H). Ensure the tab of the inserts at the rear of the shell is locked.
Place the metal fork mount (T3197-00) on a flat surface outside the box. Orient it based on your wheel size (e.g., 20"-24"-26" ATB-650C or 27"-700C). Insert the fork into the mount and tighten the wing nut clockwise. Place the bike with the attached fork mount into the box. Position the fork mount over the threaded studs protruding through the bottom of the box. Choose the pair of holes in the fork mount that allow the handlebar to be as close as possible to the front of the box without touching. Place two wing nuts over the threaded studs and tighten clockwise.
Place the fork mount on a flat surface outside the box. Orient it based on wheel size. Insert the fork into the mount and tighten the wing nut clockwise. Use washers as needed to prevent interference. Remove the front 2 or 4 handlebar stem bolts using the provided Allen wrench (B1382-00). Rotate the stem and fork so the stem faces the back wheel. Reinstall and tighten handlebar stem bolts to the manufacturer's recommended torque settings. The front brake should face the rear wheel.
Place the bike with the fork mount into the box. Position the fork mount over the threaded studs protruding through the bottom. Choose holes that allow the head tube to be as close as possible to the front of the box without touching. Place two wing nuts over the studs and tighten clockwise. Strap the handlebars to the sprocket side of the box at two points using flat nylon ties (B1220-00). If possible, lower the seat or place it in the plastic saddle travel bag (B1250-00) on the sprocket side. Crank arms should be perpendicular to the floor for best fit.
Fold the two small corrugated inserts (C3750-00) as shown (steps B-E). Insert them into the box toward the rear, lightly pressing against the bicycle's seat stays or chain stays. Do not let them touch the chainrings. Position the rear wheel to the right of center for derailleur protection. Always shift the rear derailleur to the largest rear sprocket for shipping.
Place the saddle with seatpost into the small white draw string bag (B1250-00). Secure it to the chain side of the box with one flat nylon tie (B1220-00). Use another tie to secure the bag halfway down to prevent swinging.
Place the front wheel inside the box, opposite the bicycle chain. Use two flat nylon ties (B1220-00) to secure the wheel to the side of the box.
Secure the rear wheel with one flat nylon tie (B1220-00) through the horizontal rear opening. Tie a square knot.
Fold the original shipping box in half and store it on the sprocket side of the box, between the outer shell and the large insert. This stores the container for future use and adds extra derailleur protection.
First, close the inside flap "5," then the outside flap so the "5"s match up. Next, close the flap with the aircaddy.com logo so the "6"s match up, completing the closure.
Tape the free edges of the box closed with five 8-inch strips to bridge the edges. Then, use a long, continuous strip to completely seal the edges. Print your home address and cell phone number on the label near No.6. Important: If flying commercially, do not tape the top of the box closed. Airport personnel will tape it after inspection.
If using the K8350 Aircraft Kit with the wheel truck, move the box by picking up the pointed end and rolling it away. Grasp the box using the lower, vertical slot. Lift the pointed end high enough to engage the wheels. Push or pull the AirCaddy for control.
Multiple AirCaddy containers can be stacked on top of one another or nested next to each other as shown in the diagrams.
General| Brand | AirCaddy |
|---|---|
| Model | K8350 |
| Category | Bicycle Accessories |
| Language | English |
